Additively manufactured protrusions

ABSTRACT

A computing component is described. The computing component includes a cosmetic prefabricated sheet of material. In some embodiments, the cosmetic prefabricated sheet of material may have a cosmetic surface and a protrusion surface. The computing component includes a protrusion extending from the protrusion surface of the cosmetic prefabricated sheet of material. In some embodiments, the cosmetic surface of the cosmetic prefabricated sheet of material is uniform in appearance to the naked eye. In some embodiments, the protrusion may have a base and an end. The base may have a cross-sectional width and the end may have a cross-sectional width. A difference in the cross-sectional width of the base and the cross-sectional width of the end may be less than 250 microns.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/646,715, filed Jul. 11, 2017, which is hereby incorporated byreference in its entirety.

BACKGROUND Background and Relevant Art

Use of computing devices is becoming more ubiquitous by the day.Computing devices range from standard desktop computers to wearablecomputing technology and beyond. As technology improves, computingdevices continue to decrease in size.

The subject matter claimed herein is not limited to embodiments thatsolve any disadvantages or that operate only in environments such asthose described above. Rather, this background is only provided toillustrate one exemplary technology area where some embodimentsdescribed herein may be practiced.

BRIEF SUMMARY

In one embodiment, a computing component is described. The computingcomponent includes a cosmetic prefabricated sheet of material having acosmetic surface and a protrusion surface. The computing component alsoincludes a protrusion abutting and extending from the protrusion surfaceof the cosmetic prefabricated sheet of material. The cosmetic surface ofthe cosmetic prefabricated sheet of material is uniform in appearance tothe naked eye.

In one embodiment, a computing component is described. The computingcomponent includes a cosmetic prefabricated sheet of material. Thecomputing component also includes a protrusion extending from aprotrusion surface of the cosmetic prefabricated sheet of material. Theprotrusion has a base and an end. The base has a cross-sectional widthand the end has a cross-sectional width. A difference in thecross-sectional width of the base and the cross-sectional width of theend is less than 250 microns.

In one embodiment, a computing component is described. The computingcomponent includes a cosmetic prefabricated sheet of material. Thecomputing component includes an electronic component connected to thecosmetic prefabricated sheet of material. The computing component alsoincludes a protrusion extending from a protrusion surface of thecosmetic prefabricated sheet of material. The protrusion has a base andan end. The base has a cross-sectional width and the end has across-sectional width. A difference in the cross-sectional width of thebase and the cross-sectional width of the end being less than 250microns. The protrusion shields an electronic component.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

Additional features and advantages will be set forth in the descriptionwhich follows, and in part will be obvious from the description, or maybe learned by the practice of the teachings herein. Features andadvantages of the invention may be realized and obtained by means of theinstruments and combinations particularly pointed out in the appendedclaims. Features of the present invention will become more fullyapparent from the following description and appended claims, or may belearned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otherfeatures of the disclosure can be obtained, a more particulardescription will be rendered by reference to specific embodimentsthereof which are illustrated in the appended drawings. For betterunderstanding, the like elements have been designated by like referencenumbers throughout the various accompanying figures. While some of thedrawings may be schematic or exaggerated representations of concepts, atleast some of the drawings may be drawn to scale. Understanding that thedrawings depict some example embodiments, the embodiments will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1 is an isometric top view of an embodiment of a computingcomponent;

FIG. 2 is a cross sectional view of the embodiment of a computingcomponent along line 2-2 of FIG. 1 ;

FIG. 2-1 is a cutaway cross-sectional view of the protrusion and thesheet. As shown, a first layer may be applied to the sheet;

FIG. 3 is an elevated cross-sectional view of an embodiment of aprotrusion along line 3-3 of FIG. 1 ;

FIG. 4 is a cross-sectional side view of an embodiment of a protrusionalong line 4-4 of FIG. 1 ;

FIG. 5 is a cross-sectional side view of another embodiment of acomputing component;

FIG. 6 is a cross-sectional side view of a further embodiment of acomputing component;

FIG. 7 is a cross-sectional side view of a yet further embodiment of acomputing component;

FIG. 8 is a cross-sectional side view of an embodiment of a computingcomponent with a plurality of protrusions extending from a sheet and atleast partially covered by a shield; and

FIG. 9 is a top view of another embodiment of a computing component.

DETAILED DESCRIPTION

This disclosure generally relates to computing components with one ormore additively manufactured protrusions, systems, and methods ofmanufacturing and use. More particularly, this disclosure generallyrelates to additively manufactured protrusions extending from a cosmeticsurface.

FIG. 1 is an isometric top view of an embodiment of a computingcomponent 100. The computing component 100 includes a sheet 110. Thesheet 110 may be prefabricated. In other words, the sheet 110 may bepreformed to its final shape. For example, the sheet 110 may be rolledor otherwise cold worked. The sheet 110 may include a protrusion surface112 and a cosmetic surface 116.

The sheet 110 may have a thickness 114 between the cosmetic surface andthe protrusion surface 112. The thickness may be less than 200 microns,400 microns, 600 microns, 800 microns, 1 cm, 1.5 cm, 2 cm, or valuestherebetween. The sheet 110 may be flat. For example, the sheet 110 maybe flat to within 100 microns over a 10 cm by 10 cm area, to within 150microns over a 15 cm by 15 cm area, or to within 50 microns over a 5 cmby 5 cm area.

The sheet 110 may be formed of steel, copper, aluminum, stainless steel,titanium, magnesium, other materials, or alloys thereof. In at least oneembodiment, the sheet 110 is formed of 303 half hard stainless steel.The cosmetic surface 116 may be treated. For example, the cosmeticsurface 116 may be anodized, polished, plated, painted, or otherwisetreated. The sheet 110 may have a yield stress of greater than 70 MPa,250 MPa, 500 MPa, 600 MPa, 700 MPa, 900 MPa, or values therebetween. Thesheet 110 may have a hardness of greater than Rockwell hardness of 60B,87B, 60C, or values or ranges of values therebetween.

The cosmetic surface of the sheet 110 may be uniform in appearance tothe naked eye. For example, observing the cosmetic surface of the sheet110 may show that the cosmetic sheet is free from blemishes.

The computing component 100 may include one or more protrusions 120. Theprotrusions 120 may extend from the protrusion surface 112. Theprotrusions 120 may be additively manufactured to the sheet 110. In atleast one embodiment, each protrusion 120 is formed on the sheet 110 andis not separately formed and attached to the sheet 110. The protrusions120 may have lengths (e.g., length 125, 127).

As shown, protrusions 120 may be used for attachment points (e.g.,bosses at the corners), structural reinforcements (e.g., the x-shapedprotrusions), shielding elements (e.g., FIG. 8 ), three-dimensionalcontours (e.g., FIGS. 4 and 5 ), other purposes, or combinationsthereof. The x-shaped protrusion shown in FIG. 1 may have anintersection. The intersection may form an L-, X-, Y-, or other shapedintersection. The X-shaped intersection is shown with orthogonalcorners.

FIG. 2 is a cross sectional view of the embodiment of a computingcomponent 100 along line 2-2 of FIG. 1 . An embodiment of a protrusion120-2 is shown. The protrusion 120-2 may be additively manufactured tothe sheet 110. For example, the protrusion 120-2 may be formed on thesheet 110 by Selective Laser Melting (SLM).

The protrusion 120-2 may have a base 122 and an end 124. The end 124 maybe used for structural support. For example, a separate component may beattached to the end 124. The base 122 may have a cross-sectional width126-1 and the end 124 may have a cross-sectional width 126-2. Theprotrusion 120-2 may have a difference in cross-sectional width 126-1 atthe base 122 and the cross-sectional width 126-2 at the end 124. Asshown the difference may be zero. In other embodiments, the differencemay be less than 250 microns.

As shown, the protrusion 120-2 may be applied to the protrusion surface112 in layers 130. The protrusion 120-2 may have a height 128 (e.g.,height 128-2). The height 128 may be greater than 200 microns, 300microns, 400 microns, 600 microns, 1 mm, 2.5 mm, 5 mm, or any valuetherebetween.

Additively manufactured protrusions 120-2 may differ from a manufacturedprotrusion that is adhered to the sheet 110. For example, additivelymanufactured protrusions 120-2 may have a plurality of layers 130. FIG.2-1 is a cutaway cross-sectional view of the protrusion 120-2 and thesheet 110. As shown, a first layer 130-1 may be applied to the sheet110. For example, the first layer 130-1 may be sintered to the sheet110. As the first layer 130-1 is applied to the sheet 110, heat maycreate a heat affected zone 118-2. The heat affected zone 118-2 mayextend from the protrusion surface 112 toward the cosmetic surface 116.In at least one embodiment, applying layers 130 to form the protrusion120-2 may reduce the size of the heat affected zone 118-2. A distance119-2 between the cosmetic surface 116 and the heat affected zone 118-2may be less than 20 microns, 40 microns, 60 microns, or any value orrange of values therebetween.

If the heat affected zone 118-2 reaches the cosmetic surface 116, thecosmetic surface 116 may become visually and/or structurally modified(e.g., blemished). For example, an area of the cosmetic surface 116adjacent (e.g., below) the protrusion 120-2 may have a different surfaceroughness than another area of the cosmetic surface 116 away from theprotrusion 120-2. In another example, the area of the cosmetic surface116 adjacent the protrusion 120-2 may exhibit recrystallization. Heatmay, for example, modify (e.g., passivate) the crystal structure of thesheet 110. In another example, the area of the cosmetic surface 116adjacent the protrusion 120-2 may have a different microstructure thanareas away from the protrusion 120-2. In a further example, the area ofthe cosmetic surface 116 adjacent the protrusion 120-2 may have adifferent microstructural texture than areas away from the protrusion120-2.

In at least one embodiment, a difference between an average surfaceroughness of the area of the cosmetic surface 116 adjacent theprotrusion 120-2 and an average surface roughness of the area of thecosmetic surface 116 away from the protrusion 120-2 may be less than0.01 μm Ra, 0.1 μm Ra, 0.5 μm Ra, 1 μm Ra, 5 μm Ra, 10 μm Ra, or valuestherebetween. In at least one embodiment, the surface roughness of thearea of the cosmetic surface 116 adjacent the protrusion 120-2 and thesurface roughness of the area of the cosmetic surface 116 away from theprotrusion 120-2 may be the same. In at least one embodiment, the areaof the cosmetic surface 116 adjacent the protrusion 120-2 may notexhibit recrystallization. In at least one embodiment, the surfaceroughness of the area of the cosmetic surface 116 adjacent theprotrusion 120-2 and the surface roughness of the area of the cosmeticsurface 116 away from the protrusion 120-2 have the same microstructuraltexture. In at least one embodiment, the area of the cosmetic surface116 adjacent the protrusion 120-2 and the area of the cosmetic surface116 away from the protrusion 120-2 have a uniform microstructuraltexture. In at least one embodiment, the area of the cosmetic surface116 adjacent the protrusion 120-2 and the area of the cosmetic surface116 away from the protrusion 120-2 have the same microstructuraltexture. In at least one embodiment, the microstructural texture of thearea of the cosmetic surface 116 adjacent the protrusion 120-2 and themicrostructural texture of the area of the cosmetic surface 116 awayfrom the protrusion 120-2 may be uniform. In at least one embodiment,the cosmetic surface 116 may be a class A surface. In at least oneembodiment, the cosmetic surface 116 has a uniform color. In at leastone embodiment, the cosmetic surface 116 has a surface roughness of lessthan 0.01 μm Ra, 0.1 μm Ra, 0.5 μm Ra, 1 μm Ra, 5 μm Ra, 10 μm Ra, orvalues therebetween. In at least one embodiment, the cosmetic surface116 has an average surface roughness of less than 0.5 μm Ra, 1.0 μm Ra,4 μm Ra, or values therebetween. In at least one embodiment, thecosmetic surface 116 has a uniform surface roughness.

The first layer 130-1 may form a microstructural bond with the sheet110. A second layer 130-2 may be applied to the first layer 130-1. Athird layer 130-3 and successive layers 130 may be added until theprotrusion 120-2 reaches a desired height 128. Each layer 130 has aheight 138. As shown, the first layer 130-1 has a height 138-1.

FIG. 3 is an elevated cross-sectional view of an embodiment of aprotrusion 120-3 along line 3-3 of FIG. 1 . The protrusion 120-3 forms aboss. The boss may be used to attach parts together (e.g., screws,detents, snaps).

The protrusion 120-3 may have a base 122 and an end 124. The protrusion120-3 may be rounded. The protrusion 120-3 may form an enclosure. Theprotrusion 120-3 may have an inner surface 121 and an outer surface 123.The inner surface 121 may be threaded. As shown, the protrusion 120-3,in cross-section, may have one or more thicknesses (e.g., widths 126).For example, the left side of the base 122 may have a cross-sectionalwidth 126-1-1 and the right side of the base 122 may have across-sectional width 126-1-2. The left side of the end 124 may have across-sectional width 126-2-1 and the right side of the end 124 may havea cross-sectional width 126-2-2.

The protrusion 120-3 may have a difference in cross-sectional width126-1 at the base 122 and the cross-sectional width 126-2 at the end124. As shown the difference may be zero.

The protrusion 120-3 in FIG. 3 may have cross-sectional heights 128. Theprotrusion 120-3 may have a first cross-sectional height 128-1 and asecond cross-sectional height 128-2. As shown, the first cross-sectionalheight 128-1 and the second cross-sectional height 128-2 are the same.In other embodiments, the cross-sectional heights 128 and/or widths 126may be different.

The protrusion 120-3 may include layers (not shown) and may have a heataffected zone 118-3 adjacent the protrusion 120-3. A distance 119-3between the cosmetic surface 116 and the heat affected zone 118-3 may beless than 20 microns, 40 microns, 60 microns, or any value or range ofvalues therebetween.

FIG. 4 is a cross-sectional side view of an embodiment of a protrusion120-4 along line 4-4 of FIG. 1 . The protrusion 120-4 of FIG. 4 may besimilar to the protrusions 120-2, 120-3 described in connection withFIGS. 2-3 . The protrusion 120-4 forms a three-dimensional contour. Thethree-dimensional contour may be used to retain components within thesheet 110. The protrusion 120-4 may have a base 122 and an end 124. Theprotrusion 120-4 may be rounded along one side in cross-section.

The protrusion 120-4 may have a difference in cross-sectional width126-1 at the base 122 and the cross-sectional width 126-2 at the end124. As shown the difference may be 250 microns. In other words, thecross-sectional width 126-2 may be zero at the end 124 while thecross-sectional width 126-1 may be 250 microns at the base 122. Theprotrusion 120-4 in FIG. 4 has a cross-sectional height 128.

The protrusion 120-4 may include layers (not shown) and may have a heataffected zone 118-4 adjacent the protrusion 120-4. A distance 119-4between the cosmetic surface 116 and the heat affected zone 118-4 may beless than 20 microns, 40 microns, 60 microns, or any value or range ofvalues therebetween.

FIG. 5 is a cross-sectional side view of another embodiment of acomputing component 200 with a protrusion 220 extending from a sheet210. The protrusion 220 may be similar to the protrusions 120-2, 120-3,120-4 described in connection with FIGS. 2-4 and like numbers may beused to designate like elements. The protrusion 220 forms athree-dimensional contour and a support structure 240. The supportstructure 240 may be used to support a component. For example, anothersheet, which could be similar to sheets 110, 210 may rest on and/or beaffixed to the support structure 240. The three-dimensional contour maybe used to retain components within the sheet 210. The protrusion 220may have a base 222 and an end 224. The protrusion 220 may be roundedalong one side in cross-section.

The protrusion 220 may have a difference in cross-sectional width 226-1at the base 222 and the cross-sectional width 226-2 at the end 224. Asshown the difference may be 250 microns. In other words, thecross-sectional width 226-2 may be zero at the end 224 while thecross-sectional width 226-1 may be 250 microns at the base 222. Theprotrusion 220 in FIG. 4 has a cross-sectional height 228.

The protrusion 220 may include layers (not shown) and may have a heataffected zone 218 adjacent the protrusion 220. A distance 219 betweenthe cosmetic surface 216 and the heat affected zone 218 may be less than20 microns, 40 microns, 60 microns, or any value or range of valuestherebetween.

FIGS. 6 and 7 are cross-sectional side views of embodiments computingcomponents 300, 400 with protrusions 320, 420 extending from sheets 310,410. For ease of discussion, the description will focus on thedifferences between the protrusions 320, 420 of FIGS. 6 and 7 . Theprotrusions 320, 420 may be similar to the protrusions 120, 220described in connection with FIGS. 1-5 and like numbers may be used todesignate like elements.

As shown, the protrusions 320, 420 may vary in cross-sectional widths326, 426. In the protrusion 320 shown in FIG. 6 , the cross-sectionalwidth 326-2 at the end 324 is smaller than the cross-sectional width326-1 at the base 322. In the protrusion 420 shown in FIG. 7 , thecross-sectional width 426-1 at the base 422 is smaller than thecross-sectional width 426-2 at the end 424. The difference incross-sectional widths 326, 426 may be less than 250 microns. In someembodiments, the difference in cross-sectional widths 126, 226, 326, 426may be less than 250 microns over a length. The length, in someembodiments, (e.g., from one end to another) of a protrusion 120, 220,320, 420 may be from 100 microns to 1 mm, 1 cm, 10 cm, 50 cm, otherlengths, or any values therebetween. In some embodiments, the differencein cross-sectional widths 126, 226, 326, 426 may be less than 250microns over a length of at least 250 microns, 500 microns, 750 microns,1 cm, 5 cm, 10 cm, 50 cm, or any value or range of values there between.

FIG. 8 is a cross-sectional side view of an embodiment of a computingcomponent 500 with a pair of protrusions 520-1, 520-2 extending from asheet 510 and attached to a printed circuit board (PCB) 550. Theprotrusions 520 may be similar to the protrusions 120-2, 120-3, 120-4,220, 320, 420 described in connection with FIGS. 1-7 and like numbersmay be used to designate like elements. The protrusions 520 may have abase 522 and an end 524. The PCB 550 may be secured to the ends 524-1,524-2 of the protrusions 520-1, 520-2. The protrusions 520 and the sheet510 may form a Faraday cage. The Faraday cage may shield a electroniccomponent 502 connected to the PCB 550. The electronic component 502 mayinclude a processor, memory, a communications device, input/outputdevices, other computing components or combinations thereof. One or moreof the protrusions 520 may ground the electronic component 502 and/orthe PCB 550 to the sheet 510.

The protrusion 520 may include layers (not shown) and may have a heataffected zone 518 adjacent the protrusion 520. A distance 519 betweenthe cosmetic surface 516 and the heat affected zone 518 may be less than20 microns, 40 microns, 60 microns, or any value or range of valuestherebetween.

FIG. 9 is a top view of an embodiment of a computing component 600. Thecomputing component 600 may include a sheet 610 and plurality ofprotrusions 620 extending from the sheet. The protrusions 620 may besimilar to the protrusions 120, 220, 320, 420, 520 described inconnection with FIGS. 1-8 and like numbers may be used to designate likeelements.

The sheet has multiple, support protrusions 620-1, multiple bossprotrusions 620-2, and a larger support portion 630-3. One or more bossprotrusions 620-2 may abut one or more support protrusions 620-1. Forexample, one or more support protrusions 620-1 may abut one or more bossprotrusions 620-2. As shown, the one or more support protrusions 620-1may share a wall with one or more boss protrusions 620-2 and/or may abuta will of one or more boss protrusions 620-2.

A method of manufacturing a computing component, such as the computingcomponents 100, 200, 300, 400, 500, 600 may include fastening a sheetwithin an additive manufacturing apparatus. A plurality of layers may besintered to the sheet. Sintering may create a heat affected zone. Theheat affected zone may not extend to a cosmetic surface of the sheet.

The articles “a,” “an,” and “the” are intended to mean that there areone or more of the elements in the preceding descriptions. The terms“comprising,” “including,” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. For example, anyelement described in relation to an embodiment herein may be combinablewith any element of any other embodiment described herein. Numbers,percentages, ratios, or other values stated herein are intended toinclude that value, and also other values that are “about” or“approximately” the stated value, as would be appreciated by one ofordinary skill in the art encompassed by embodiments of the presentdisclosure. A stated value should therefore be interpreted broadlyenough to encompass values that are at least close enough to the statedvalue to perform a desired function or achieve a desired result. Thestated values include at least the variation to be expected in asuitable manufacturing or production process, and may include valuesthat are within 5%, within 1%, within 0.1%, or within 0.01% of a statedvalue.

A person having ordinary skill in the art should realize in view of thepresent disclosure that equivalent constructions do not depart from thespirit and scope of the present disclosure, and that various changes,substitutions, and alterations may be made to embodiments disclosedherein without departing from the spirit and scope of the presentdisclosure. Equivalent constructions, including functional“means-plus-function” clauses are intended to cover the structuresdescribed herein as performing the recited function, including bothstructural equivalents that operate in the same manner, and equivalentstructures that provide the same function. It is the express intentionof the applicant not to invoke means-plus-function or other functionalclaiming for any claim except for those in which the words ‘means for’appear together with an associated function. Each addition, deletion,and modification to the embodiments that falls within the meaning andscope of the claims is to be embraced by the claims.

It should be understood that any directions or reference frames in thepreceding description are merely relative directions or movements. Forexample, any references to “front” and “back” or “top” and “bottom” or“left” and “right” are merely descriptive of the relative position ormovement of the related elements.

The present disclosure may be embodied in other specific forms withoutdeparting from its spirit or characteristics. The described embodimentsare to be considered as illustrative and not restrictive. The scope ofthe disclosure is, therefore, indicated by the appended claims ratherthan by the foregoing description. Changes that come within the meaningand range of equivalency of the claims are to be embraced within theirscope.

What is claimed is:
 1. A method of manufacturing a computing component,comprising: positioning a cosmetic prefabricated sheet of materialincluding a cosmetic surface and a protrusion surface; forming aprotrusion on the protrusion surface of the cosmetic prefabricated sheetof material by selective laser melting a plurality of layers of theprotrusion including an innermost layer and an outermost layer formedabove the innermost layer; and creating a heat affected zone whileforming each of the plurality of layers of the protrusion that does notextend to the cosmetic surface of the cosmetic prefabricated sheet ofmaterial based on the protrusion being formed of the plurality ofselective laser melted layers.
 2. The method of claim 1, wherein adistance between the heat affected zone and the cosmetic surface isgreater than 20 μm.
 3. The method of claim 1, further comprising formingone or more intermediate layers of the protrusion on the innermost layerof the protrusion.
 4. The method of claim 3, wherein forming the one ormore intermediate layers of the protrusion further includes forming theone or more intermediate layers such that the heat affected zone doesnot extend to the cosmetic surface of the cosmetic prefabricated sheetof material.
 5. The method of claim 1, wherein forming the innermostlayer of the protrusion comprises forming a microstructural bond betweenthe innermost layer and the cosmetic prefabricated sheet of material. 6.The method of claim 1, wherein after forming the innermost layer of theprotrusion, the cosmetic surface of the cosmetic prefabricated sheet ofmaterial does not exhibit recrystallization.
 7. The method of claim 1,wherein an area of the cosmetic surface beneath the protrusion and anarea of the cosmetic surface adjacent the protrusion have the samemicrostructural texture.
 8. The method of claim 1, wherein after formingthe innermost layer of the protrusion, the cosmetic surface has anaverage surface roughness of less than 2 μm Ra.
 9. The method of claim1, wherein the cosmetic prefabricated sheet of material has a thicknessless than 2 mm.
 10. The method of claim 1, wherein the cosmeticprefabricated sheet of material is flat to within 100 microns over a 10cm by 10 cm area.
 11. A method of manufacturing a computing component,comprising: positioning a cosmetic prefabricated sheet of materialincluding a cosmetic surface and a protrusion surface; using SelectiveLaser Melting (SLM): forming, on the protrusion surface of the cosmeticprefabricated sheet of material, a protrusion having a plurality oflayers and being configured as an attachment point or a structuralreinforcement for a computing device component; forming the protrusionincluding: forming an innermost layer of the protrusion on theprotrusion surface of the cosmetic prefabricated sheet of material, theinnermost layer comprising a base of the protrusion; and forming anoutermost layer of the protrusion above the innermost layer, theoutermost layer of the protrusion comprising an end of the protrusion.12. The method of claim 11, wherein the protrusion has a height from thebase to the end of greater than 600 microns.
 13. The method of claim 11,wherein the protrusion forms an L-shape with an orthogonal corner asviewed from above the protrusion surface.
 14. The method of claim 11,wherein the protrusion forms a boss.
 15. The method of claim 14, whereinthe protrusion includes a support protrusion that forms a straightsection connected to the protrusion that forms the boss.
 16. The methodof claim 11, wherein the cosmetic prefabricated sheet of material has ayield stress of greater than 500 MPa.
 17. The method of claim 11,wherein the cosmetic prefabricated sheet of material has a hardness ofgreater than 50 Rockwell Hardness B.
 18. The method of claim 11, whereinthe cosmetic prefabricated sheet of material is cold worked.
 19. Themethod of claim 1, wherein the protrusion has a difference incross-sectional width across a height of the protrusion that is lessthan 250 microns.
 20. The method of claim 11, wherein the base of theprotrusion has a base cross-sectional width and the end of theprotrusion has an end cross-sectional width, and wherein the differencebetween the base cross-sectional width and the end cross-sectional widthis less than 250 microns.